Plastic core attachment for a push-pull cable assembly

ABSTRACT

A motion transmitting cable assembly includes a cable having a conduit and a core longitudinally movable within the conduit, a core attachment secured to an end of the core, and a conduit abutment fitting secured to an end of the conduit. The core attachment is molded of plastic and is over-molded onto the end of the core. The core is preferably provided with both an upset and a wire wrap within the core attachment. The core attachment includes a terminal and a rod extending from the terminal and is molded as a unitary component. A guide tube extends from the conduit abutment fitting and slidably receives the rod therein. The core meets the core attachment within the guide tube and preferably extends within the rod for the entire length of the rod and a portion of the terminal.

CROSS-REFERENCE TO RELATED APPLICATIONS

Not Applicable

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH

Not Applicable

REFERENCE TO MICROFICHE APPENDIX

Not Applicable

FIELD OF THE INVENTION

The present invention generally relates to a motion-transmittingpush-pull cable assembly and, more particularly, to a core attachmentfor the push-pull cable assembly.

BACKGROUND OF THE INVENTION

Motion-transmitting control cable assemblies, sometimes referred to as“Bowden cables” or “push-pull cables,” are used for transmitting bothforce and travel along a path in aircraft, automotive, and marineenvironments. These cable assemblies can be used for transmitting forceand motion in push/pull type applications. One example of a specific useof such remote control cable assemblies is positioning automatictransmission shift members in automobiles.

A motion-transmitting remote control cable assembly typically includes aflexible core slidably enclosed within a flexible outer sheath orconduit. The core is adapted at one end to be attached to a member to becontrolled whereas the other end is attached to an actuator forlongitudinally moving the core element within the outer sheath. The endsof the outer sheath are secured by conduit abutment fittings to supportstructures or abutment members. Typically, steel rods are crimped toends of the core. Each steel rod typically has an over-molded terminalon the end of the rod which can be connected to the control member andthe actuator. The rod ends or core attachments are relatively heavy andexpensive to manufacture. Additionally, the rod end or core attachmentis typically slidably received in a guide tube extending from theconduit abutment fitting with the core meeting the steel rod within theguide tube. Such a structure limits the available manufacturing andassembly methods for the cable assembly.

In the automobile industry, there is a never ending desire to simplifyand/or speed up the assembly process. There is also a never endingdesire to reduce cost and weight of components without negativelyaffecting performance. Accordingly, there is a need in the art for animproved core attachment for a control cable assembly.

SUMMARY OF THE INVENTION

The present invention provides a core attachment which addresses atleast some of the above-noted problems of the related art. According tothe present invention, a motion transmitting cable assembly comprises,in combination, a cable having a conduit and a core longitudinallymovable within the conduit and a core attachment secured to an end ofthe core. The core attachment is molded of plastic and is over-moldedonto the end of the core.

According to another aspect of the present invention, a motiontransmitting cable assembly comprises, in combination, a cable having aconduit and a core longitudinally movable within the conduit, a coreattachment secured to an end of the core, and a conduit abutment fittingsecured to an end of the conduit. The core attachment is molded ofplastic and is over-molded onto the end of the core. The core attachmentincludes a rod with the core extending within the rod for at least aportion of the length of the rod. A guide tube extends from the conduitabutment fitting and slidably receives the rod therein. An end of thecore attachment is located within the guide tube and the core extendsinto the guide tube to the core attachment. At least a portion of theguide tube is adapted to be laterally attached over the core attachmentand the core at a juncture of the core attachment and the core.

According to yet another aspect of the present invention, a motiontransmitting cable assembly comprises, in combination, a cable having aconduit and a core longitudinally movable within the conduit, a coreattachment secured to an end of the core, and a conduit abutment fittingsecured to an end of the conduit. The core attachment is molded ofplastic and is over-molded onto the end of the core. The core isprovided with at least one of an upset and a wire wrap within the coreattachment. The core attachment includes a terminal and a rod extendingfrom the terminal and is molded as a unitary component. The core extendswithin the rod for at least a portion of the length of the rod. A guidetube extends from the conduit abutment fitting and slidably receives therod therein. An end of the core attachment is located within the guidetube and the core extends into the guide tube to the core attachment. Atleast a portion of the guide tube is adapted to be laterally attachedover the core attachment and the core at a juncture of the coreattachment and the core. This is known as overlap between the guide tubeand end portion of the rod.

According to yet another aspect of the present invention, push-pullmotion transmitting cable assembly for a motor vehicle comprises, incombination, a cable having a conduit and a core longitudinally movablewithin the conduit, and a core attachment secured to an end of the core.The conduit comprises only nonmetallic materials. Preferably core alsocomprises only nonmetallic materials. More preferably, the entire cableassembly comprises only nonmetallic materials.

From the foregoing disclosure and the following more detaileddescription of various preferred embodiments it will be apparent tothose skilled in the art that the present invention provides asignificant advance in the technology of core attachments for controlcable assemblies. Particularly, the invention provides an easilymanufactured, low cost and low weight device which maintains desiredperformance requirements. Additional features and advantages of variouspreferred embodiments will be better understood in view of the detaileddescription provided below.

BRIEF DESCRIPTION OF THE DRAWINGS

These and further features of the present invention will be apparentwith reference to the following description and drawings, wherein:

FIG. 1 is a perspective view of a push-pull cable assembly according apreferred embodiment of the present invention;

FIG. 1A is an enlarged cross-sectional view of a cable of the cableassembly of FIG. 1;

FIG. 1B is an enlarged cross-sectional view of a first end of the cableassembly of FIG. 1, wherein the core and core attachment are removed forclarity;

FIG. 1C is an enlarged cross-sectional view of a second end of the cableassembly of FIG. 1, wherein the core and core attachment are removed forclarity;

FIG. 2 is a perspective view of a conduit abutment fitting and a jointportion of a guide tube of the cable assembly of FIG. 1;

FIG. 3 is a perspective view of the joint portion of the guide tube ofFIG. 2;

FIG. 4 is a perspective view of an extension portion of the guide tubeof the cable assembly of FIG. 1;

FIG. 5 is a perspective view of the extension portion of FIG. 4 beinginstalled onto the joint portion of FIG. 3;

FIG. 6 is a perspective view of a core attachment of the cable assemblyof FIG. 1 being installed onto a control member;

FIG. 7 is a perspective view, in cross-section, of the core attachmentof FIG. 6;

FIG. 8 is an enlarged, fragmented perspective view of a variation of thecore attachment of FIGS. 6 and 7;

FIG. 9 is an enlarged, fragmented perspective view of an end of a coreto which the core attachment is formed as shown in FIG. 8;

FIG. 10 is a perspective view similar to FIG. 6 but showing anothervariation of the core attachment of FIGS. 6 and 7;

FIG. 11 is a perspective view similar to FIG. 6 but showing anothervariation of the core attachment of FIGS. 6 and 7;

FIG. 12 is a perspective view similar to FIG. 7 but showing anothervariation of the core attachment of FIGS. 6 and 7;

FIG. 13 is a fragmented perspective view, partially in cross-section, ofa forward end of the core attachment of FIG. 12;

FIG. 14 is a perspective view, partially in cross-section, of a rearwardend of the core attachment of FIG. 12;

FIG. 15 is a perspective view of a molding operation during manufactureof the cable assembly of FIG. 1;

FIG. 16 is a perspective view of a guide tube attachment operationduring manufacture of the cable assembly of FIG. 1;

FIG. 17 is a perspective view of a push-pull cable assembly according asecond preferred embodiment of the present invention;

FIG. 18 is a perspective view of conduit abutment fittings of the cableassembly of FIG. 17, wherein the conduit abutment fittings have externalballs for cooperation with the guide tubes;

FIG. 19 is a perspective view of the guide tube for the cable assemblyof FIGS. 17 and 18;

FIG. 20 is a perspective view of a variation of the guide tube of FIG.19;

FIG. 21 is a perspective view of the guide tube of FIG. 19 beinginstalled onto the ball of the conduit abutment fitting of FIG. 18;

FIG. 22 is a perspective view of a molding operation during manufactureof the cable assembly of FIG. 17; and

FIG. 23 is a perspective view of a guide tube attachment operationduring manufacture of the cable assembly of FIG. 17.

It should be understood that the appended drawings are not necessarilyto scale, presenting a somewhat simplified representation of variouspreferred features illustrative of the basic principles of theinvention. The specific design features of the cable assembly asdisclosed herein, including, for example, specific dimensions,orientations, and shapes of the various components will be determined inpart by the particular intended application and use environment. Certainfeatures of the illustrated embodiments have been enlarged or distortedrelative to others to facilitate visualization and clear understanding.In particular, thin features may be thickened, for example, for clarityor illustration. All references to direction and position, unlessotherwise indicated, refer to the orientation of the cable assembliesillustrated in the drawings. In general, up or upward refers to anupward direction generally in the plane of the paper in FIGS. 1 and 17and down or downward refers to a downward direction generally in theplane of the paper in FIGS. 1 and 17. Also in general, fore or forwardrefers to a direction generally toward the left in the plane of thepaper in FIGS. 1 and 17, that is toward the end of the cable core, andaft or rearward refers to a direction generally toward the right in theplane of the paper in FIGS. 1 and 17, that is away from the end of thecable core.

DETAILED DESCRIPTION OF CERTAIN PREFERRED EMBODIMENTS

It will be apparent to those skilled in the art, that is, to those whohave knowledge or experience in this area of technology, that many usesand design variations are possible for the motion-transmitting controlcable assemblies disclosed herein. The following detailed discussion ofvarious alternative and preferred embodiments will illustrate thegeneral principles of the invention with reference to a push-pull cableassembly for use with a motor vehicle transmission system. Otherembodiments suitable for other applications will be apparent to thoseskilled in the art given the benefit of this disclosure.

The term “snap-fit” or “snap-lock” is used herein and in the claims tomean a connection between at least two components wherein at least oneof the components has a protrusion and/or abutment which engages theother component to form an interlock or interference which retains thecomponents together when they are connected and at least one of thecomponents has a resiliently deformable or deflectable portion such thatthe deflectable portion deflects to remove the interference as the partsare brought together and resiliently snaps back to reform theinterference when the components are together. The term “unitary” isused herein and in the claims to mean a member made of a singlecontinuous material, such as, for example a molded component. The term“integral” is used herein and in the claims to mean two or more membersthat are rigidly secured together such as, for example, two membersconnected by over-molding, fasteners or the like.

Referring now to the drawings, FIG. 1 shows a push-pull cable assembly10 according to a preferred embodiment of the present invention whichconnects a transmission assembly to a shifter assembly of a motorvehicle, such as an automobile. While the illustrated embodiments of thepresent invention are particularly adapted for use with an automobile,it is noted that the present invention can be utilized with any motorvehicle having a control cable including trucks, buses, vans,recreational vehicles, earth moving equipment and the like, off roadvehicles such as dune buggies and the like, air borne vehicles, andwater borne vehicles. While the illustrated embodiments of the presentinvention are particularly adapted for use with a transmission system,it is also noted that the present invention can be utilized with othermotor vehicle systems such as, for example, a parking brake,accelerator, hood release, brake release, trunk release, park lock, tiltwheel control, fuel filler door, and/or hydraulic control cables. Whilethe illustrated embodiments of the present invention are particularlyadapted for the transmission end of the cable, it is further noted thatfeatures of the present invention can be utilized at the shifter end ofthe cable.

As best shown in FIGS. 1 and 1A, the illustrated push/pull cableassembly 10 includes a push-pull cable 12 having a flexible outer sheathor conduit 14 and a flexible inner core 16 longitudinally slidablewithin the conduit 14. For push-pull applications in automotiveapplications, the conduit 14 typically includes an interiorthermoplastic tube or liner 14 a. The liner 14 a forms the insidediameter or passage 14 b of the conduit 14. Exterior to the liner 14 a,a reinforcing element 14 c, such as a plurality of metal wires helicallywrapped about the liner 14 a, is provided to add strength to thethermoplastic liner 14 a. The reinforcing element 14 c gives addedstrength for the compression and tension loads seen in push-pullapplications. After the reinforcing element 14 c is applied about theliner 14 a, an outer coating or jacket 14 d of flexible thermoplasticmaterial is applied to hold the reinforcement member 14 c in relation tothe liner 14 a and fully encapsulate the sub-assembly. The outer coating14 d is typically applied through a high temperature extrusion process.Through extrusion, an outside diameter is formed around the sub-assemblyand the conduit 14 can be cut to a desired length.

Alternatively, the conduit 14 can be constructed to eliminate the use ofmetal in the reinforcing element 14 c so that the conduit 14 isconstructed entirely of non-metallic materials. Optional materials forthe reinforcing element 14 c may include thermoplastic wires such asNylon Monofilament 610, reinforced Nylon 66, or any suitable reinforcedthermoplastic in extrusion form, such as a thermoplastic wire. Alternatebundle configurations and alternate shapes can be arranged to achieve afinal form or interlocking design. The amount of load carryingcapability of the conduit 14 can be customized per application byaltering the design of the reinforcing element. As well, a reinforcingelement 14 c may include a thermoplastic that makes use of carbonnanotube (CNT) technology. Such a reinforcing element 14 c may have thestrength equivalency of steel and be quite suitable for conduitconstruction, all the time replacing metal from the conduitconstruction.

Alternatively, the reinforcing element 14 c may be constructed ofcomposite fibers such as carbon, fiberglass, or Kevlar. There aremultiple options to arranging the reinforcing element 14 c. The shape ofthe individual elements can vary along with element size, helicalpattern, and layers of wrap. A multi-layer design may be favorable withcross-weaving for strength. It is noted that the conduit 14 canalternatively have any other suitable construction depending upon therequirements of a particular application. As described above, theconduit 14 can be formed of a combination of metal and plastic or othernonmetallic materials, or of entirely plastic or other nonmetallicmaterials depending upon the requirements of a particular application.

Use of the above described constructions can eliminates metal from theconduit 14. Weight savings and cost may be reduced by the above methodsof construction. As well, the conduit 14 may see increased flexibilityas compared to conduit 14 made with steel wire construction. Steel wiresare often rigid and the final construction of the conduit 14 maintainsthat rigidity after completion. This rigidity of the conduit 14 issometimes an issue when the cables 12 are being installed and routedthroughout a vehicle' structure. The above methods may improve theflexibility of the cable 12 and allow a smaller radius bend condition toexist when the cable 12 is installed in a vehicle.

The core 16 typically consists of a strand assembly made up of metalwire. The metal wires are wound in different configurations dependingupon the application. The core 16 is used for push-pull loading andtypically has a center wire 16 a, or a small wire bundle. To strengthenthe center wire 16 a, a reinforcing element 16 b is provided such as,for example, a plurality of outer wires, or wire bundles, helicallywound around the center wire 16 a. As with the reinforcing element 14 cfor the conduit liner 14 a, the reinforcing element 16 b for the core 16provides support for the center wire 16 a.

Alternatively, the core 16 can be constructed to eliminate the use ofmetal so that the core 16 is constructed entirely of non-metallicmaterials. The center wire 16 a and the outer wires 16 b can be made ofnonmetallic materials such as, Nylon Monofilament 610, reinforced Nylon66, or any suitable reinforced thermoplastic in extrusion form. As inthe conduit construction, alternate bundle configurations and alternateshapes can be arranged to achieve a final form or interlocking designfor the core. Design of the core 16 can also make use of newtechnologies in thermoplastics such as the above mentioned carbonnanotube modifications for strength. The final nonmetallic core mayconsist of a combination of thermoplastic wires plus some form of fiberwrap. As with the conduit construction, the reinforcing element 16 b forthe core 16 may be constructed of composite fibers such as carbon,fiberglass, or Kevlar. There are multiple options to arranging thereinforcing element 16 b. The shape of the individual reinforcingelements 16 b can vary along with element size, helical pattern, andlayers of wrap. A multi-layer design may be favorable with cross-weavingfor strength. The goal is to provide strength for both tension andcompression loading. It is noted that the core 16 can alternatively haveany other suitable construction depending upon the requirements of aparticular application. As described above, the core 16 can be formed ofmetal, plastic or other nonmetallic materials, or a combination of metaland plastic or other nonmetallic materials depending upon therequirements of a particular application.

If the above nonmetallic constructions for the conduit 14 and the core16 are utilized along with the use of thermoplastic core attachments 22(as described in more detail hereinafter), then a push-pull cableassembly 10 could be constructed without the use of metal in any of thecomponents. Typical conduit abutment fittings already take advantage ofthe use of thermoplastics and thermo-elastic polymers. With the abovementioned constructions, an “All-Plastic” cable assembly is possible.

As best shown in FIGS. 1 and 1B, a first end of the conduit 14 issecured to a conduit abutment fitting assembly or end fitting assembly18. A guide tube 20 extends from the forward end of the conduit abutmentfitting assembly 18. The illustrated guide tube 20 is of the swivel tubetype as described in more detail hereinafter. A first end of the core 16extends longitudinally out of the first open end of the conduit 14 andpartially through the conduit abutment fitting assembly 18 and isrigidly connected to a core attachment 22 within the guide tube 20. Thecore attachment 22 is slidably received within the guide tube 20 forsliding longitudinal movement therein. The illustrated core attachment22 is adapted to be operatively connected to a connection pin 24 ofcontrol member such as, for example, a transmission lever. It is notedthat the core attachment 22 can alternatively be adapted to be connectedto the control member in any other suitable manner and/or to any othersuitable type of control member. It is also noted that the cableassembly 10 can alternatively be provided with an adjuster of anysuitable type (for example, see the adjuster 25 in FIG. 17).

As best shown in FIGS. 1 and 1C, the second open end of the conduit 14is secured to a second conduit abutment fitting assembly 18′ and thesecond end of the core 16 is rigidly connected to a second coreattachment 22′ within a guide tube 20′ of the second conduit abutmentfitting assembly 18′. The illustrated second core attachment 22′ isadapted to be operatively connected to a connection pin 24 of controlmember such as, for example, a shifter lever. It is noted that thesecond core attachment 22′ can alternatively be adapted to be connectedto the control member in any other suitable manner and/or to any othersuitable type of control member.

In operation, movement of the shifter lever by the operator moves thesecond core attachment 22′ to push or pull the core 16. The longitudinalmovement of the core 16 within the conduit 14 pushes or pulls the firstcore attachment 22 to operate the transmission lever to change gears ina desired manner. The core attachments 22, 22′ longitudinally movewithin the guide tubes 20, 20′ to define a linear line of force as thecore attachments 22, 22′ are actuated to axially move within the guidetubes 20, 20′. Thus, longitudinal movement of the core 16 and the coreattachments 22, 22′ actuates the control member. The flexible conduitand core 14, 16 allow the cable 12 to be routed along a desired path,which is typically not linear. The illustrated guide tubes 20, 20′ areswivel type guide tubes which can pivot to allow the orientation of thecore attachments 22, 22′ relative to the conduit abutment fittingassemblies 18, 18′ to account for rotational motion of the controlmembers.

As best shown in FIG. 2, the illustrated first and second conduitabutment fitting assemblies 18, 18′ each include a conduit abutmentfitting or main body 26, 26′ and the guide tubes 20, 20′ forwardlyextend from the conduit abutment fittings 26, 26′. The illustratedconduit abutment fittings 26, 26′ are each adapted to be secured tostationary mounting brackets to form stationary locations for the endsof the conduit 14. The illustrated guide tubes 20, 20′ are each securedto the conduit abutment fittings 26, 26′ with a ball and socket orswivel joint 28, 28′ (FIGS. 1B and 1C) so that the guide tubes 20, 20′can pivot relative to the conduit abutment fittings 26, 26′. Theillustrated first conduit abutment fitting 26 is of the type which has asocket 31 formed therein and is assembled with the guide tube 20 and hasa retainer or lock cap 30 which holds the assembly together. Theillustrated second conduit abutment fitting 26′ is of the type which isover-molded onto the guide tube 20′ to form the socket 31. It is notedthat the conduit abutment fitting assemblies 18, 18′ can be of anysuitable type depending of the requirements of the application. Becausethe ends of the illustrated cable assembly 10 are substantially the samewith respect to the remaining description, only the first end will bedescribed in detail hereinafter.

As best shown in FIGS. 1 to 3, the illustrated guide tube 20 isgenerally tubular-shaped having a generally cylindrical-shaped outersurface and a longitudinally extending central opening or passage 32. Atleast a forward portion of the passage 32 is sized and shaped for closesliding receipt of the core attachment 22 therein. The rearward end ofthe passage 32 is preferably expanded to eliminate sharp edges which mayabrade the core 16 which passes into the rearward end of the passage 32.The rearward end of the illustrated guide tube 20 is provided with agenerally spherical-shaped ball 34. The ball 34 is sized and shaped forreceipt within the internal socket 31 of the conduit abutment fitting 26to form the ball and socket type swivel joint 28. It is noted that theball and socket joint 28 can be adapted to be a drop-in, push-in,snap-over, or molded-over type connection as desired. The guide tube 20is preferably adapted to have a pull-off load of at least 180N to 650Nat 20 degrees C. and preferably has an articulation angle of at least 7degrees in all directions with an articulation force of no more than4.5N.

As best shown in FIGS. 1 to 4, the illustrated guide tube 20 isconstructed of two separate and distinct components that are securedtogether during assembly of the cable assembly 10 as described in moredetail hereinafter. The illustrated guide tube 20 includes a joint orinternal member 36 secured to and forwardly extending from the conduitabutment fitting 26 and an extension or external member 38 secured toand forwardly extending from the joint member 36. The members 36, 38 arepreferably sized so that the extension member 38 covers the rearward endof the core attachment 22 throughout its stroke of axial movement, thatis, the overlap between the guide tube 20 and the core attachment 22(best shown in FIG. 16).

As best shown in FIG. 3, the joint member 36 forms the rear end of theguide tube 20. The joint member 36 is generally tubular-shaped having agenerally cylindrical-shaped outer surface and a rearward portion of thelongitudinally extending central opening or passage 32 extendstherethrough. The joint member 36 has the ball 34 formed at the rear endthereof. The forward end of joint member 36 is provided with a pluralityof circumferentially extending and axially spaced-apart grooves 40 onthe outer surface which cooperate with the extension member 38 asdescribed in more detail hereinafter. The illustrated joint member 36has three grooves 40 but any other suitable quantity can bealternatively utilized. The joint member 36 is preferably of unitaryconstruction and a separate component from the extension member 38 andis preferably molded of a plastic material but any other suitablematerial can be alternatively utilized.

As best shown in FIGS. 4 and 5, the extension member 38 forms theforward end of the guide tube 20. The extension member 38 has a first orleft portion 38 a and a second or right portion 38 b that cooperate toform a generally tubular-shape having a generally cylindrical-shapedouter surface and a forward portion of the longitudinally extendingcentral opening or passage 32 extends therethrough. The first and secondportions 38 a, 38 b have a parting plane that is parallel to andcontains the central axis 42 of the passage 32. The illustrated firstand second portions 38 a, 38 b are connected by a “living” or unitaryhinge 44 located at a rearward end of the extension member 38. Theliving hinge 44 enables the extension member 38 to be formed as aunitary component that can be folded over or wrapped around the jointmember 36 and the core 16 in a lateral direction rather than axiallyextending the core 16 through the passage 32 as described in more detailhereinafter. It is noted that the extension member 38 can alternativelybe formed as two separate components and/or the extension member 38 canhave more than two portions forming the passage 32. The illustratedfirst and second portions 38 a, 38 b are also provided with a pluralityof snap-lock connections 46 which secure the first and second portions38 a, 38 b together about the joint member 36 and the core 16. Theillustrated first and second portions 38 a, 38 b are provided with threesnap-lock connections 46: two at a forward end of the extension member38 at opposite sides of the passage 32 and one at a rearward end of theextension member 38 at a side of the passage 32 opposite the hinge 44.It is noted that any other suitable quantity of snap-lock connections 46can alternatively be utilized and/or that any other suitable type ofconnections can alternatively be utilized.

As best shown in FIGS. 4 and 5, the rearward end of the illustratedpassage 32 forms a receptacle 48 for receiving the forward end of thejoint member 36. The receptacle is provided with a plurality ofcircumferentially extending and axially spaced-apart tongues orprotrusions 50 which extend into the grooves 40 of the joint member 36to form an interlock in the axial direction to substantially preventrelative longitudinal movement between the joint member 36 and theextension member 38. It is noted that the extension member 38 and thejoint member 36 can alternatively be secured together in any othersuitable manner. The extension member 38 is preferably of unitaryconstruction and a separate component from the joint member 36 and ispreferably molded of a plastic material but any other suitable materialcan be alternatively utilized.

As best shown in FIGS. 6 and 7, the illustrated core attachment 22includes a terminal 52, an isolator 54 within the terminal 52, and a rod56 rearwardly extending from the terminal 52 and secured to the core 16.The illustrated terminal 52 has a main portion or head 58 and an endportion or attachment 60 extending rearwardly from the head 58. Theillustrated head 58 is generally annular shaped and is adapted toreceive the connecting pin 24 as is known in the art. The attachment 60is generally cylindrically shaped and rearwardly from the head generallyperpendicular to the head. That is, the central axis of the head 58 issubstantially perpendicular to the central axis of the attachment 60.The attachment 60 is adapted to connect or attach the rod 56 to the head58.

The isolator 54 is located within the opening of the head 58 and issized and shaped to prevent direct contact between the head 58 and theconnecting pin 24. The isolator 54 is preferably molded of a suitablevibration damping material such as an elastic polymer, rubber or thelike. It is noted that alternatively the isolator 54 can be eliminated,of integral construction, and/or formed at least partially of any othersuitable material. For example, the head 58 can have integral plasticprongs that contact directly with the connection pin 24.

The illustrated rod 56 is elongate and rearwardly extends from theattachment 60 of the core attachment 22. The rod 56 is sized and shapedto be slidingly received within the forward end of the passage 32 of theguide tube 20. The illustrated rod 56 is generally cylindrically shapedhaving a generally circular cross-section to cooperate with the guidetube passage 32 which is also generally circular in cross-section. It isnoted that the rod 56 can alternatively have other suitable shapes. Theillustrated terminal and rod 52, 56 are of unitary or one-piece,construction and molded of a plastic material but any other suitablematerial can be alternatively utilized. It is noted that alternatively,the terminal and rod 52, 56 can be constructed as separate componentsand secured together. For example, the rod 56 can be formed of metal rodand the terminal 52 can be formed of a plastic material over-molded ontothe forward end of the rod 56.

The illustrated unitary terminal and rod 52, 56 are molded over the endof the core 16 (best seen in FIG. 7) to secure the core 16 to the rod56. The components 16, 56 are bonded together as the plastic is formedaround the core 16. The illustrated core 16 extends along the centralaxis of the rod 56 and the attachment 60. The illustrated core 16extends entirely through the rod 56 and substantially through the rodend attachment 60. It is noted that the pull out strength of the coreattachment 22, that is the load at which the core 16 can be separatedfrom core attachment 22, is improved by increasing the length of thecore 16 that is within the core attachment 22. The core 16 preferablyextends for at least half of the length of the rod 56, and morepreferably extends at least the entire length of the rod 56, and evenmore preferably for the entire length of the rod 56 and at least aportion of the rod end attachment 60, and even more preferably for theentire length of the rod 56 and at least a substantial portion of therod end attachment 60. It is also noted that the core 16 canalternatively be secured to the rod 56 in any other suitable manner. Forexample, the rod 56 can be crimped to the core 16 when the rod 56 isformed of metal. The first core attachment 22 (which is the transmissionend outside the vehicle) is preferably adapted to withstand a tensionload of at least 667N at 149 degrees C. and compression load of at least338.8N at 149 degrees C. The second core attachment 22′ (which is theshifter end inside the vehicle) is preferably adapted to withstand atension load of at least 667N at 82 degrees C. and compression load ofat least 338.8N at 82 degrees C.

As best shown in FIGS. 8 and 9, the end of the core 16 can be providedwith an upset 66 which will assist bonding of the core attachment 22 tothe core 16 to improve the pull out load. The illustrated upset 66 isformed by compressing the end of the external wires 16 b so thatexternal wires 16 b flare outwards to form an arch-shaped protrusionnear the end of the core 16 which protrudes radially outward from thecenterline of the core 16. The upset 66 extends radially outward agreater distance than remaining portion of the core 16 to form amechanical lock or interlock in the axial direction which resists thecore 16 from pulling out of the core attachment 22 upon the applicationof axial loads. It is noted that the upset 66 and/or the axial interlockcan alternatively be formed in any other suitable manner.

FIG. 10 illustrates that the terminal head 58 can have otherconfigurations. The illustrated head 58′ has integral plastic prongsthat contact directly with the connection pin 24. In this variation ofthe head 58′ isolator 54 is eliminated.

FIG. 11 illustrates that the rod 56 can have other configurations. Theillustrated rod 56′ is substantially square in cross-section. Suchnon-circular cross-section can be advantageous when improved strength isdesired and/or it is desired to limit rotational movement of the rod 56′within the guide tube 20. It is noted that the guide tube is providedwith a cooperating shape.

As best shown in FIGS. 12 to 14, the end of the core 16 within the coreattachment 22 can be provided with a wrap 68 prior to over-molding thecore attachment 22 which will assist bonding of the core attachment 22to the core 16 to improve the pull out load and to stiffen the rod 56with regard to side loading or buckling. The illustrated wrap 68 isformed by helically wrapping a flat metal wire about the core 16. It isnoted that the wrap 68 can alternatively be formed any other suitableshape of wire or formed any other suitable type of wrap such as, forexample, a fiber wrap. It is noted that the wrap 68 can alternatively beformed of any other suitable material such as a plastic or othernon-metallic. The illustrated wrap 68 extends substantially the entirelength of core 16 within the core attachment 22. It is noted, however,that the wrap 68 can alternatively extend a shorter distance if desired.The wrap 68 is preferably wrapped in a manner to form a helical grooveor gap 70 so that plastic flows into the gap 70 during the over-moldingprocess to form an interlock in the axial direction which resists thecore 16 from pulling out of the core attachment 22 upon the applicationof axial loads. The illustrated wrap 68 is fully contained within andsealed by the molded plastic core attachment 22 which allows metal typefor the wrap 68 to be selected with out a concern for corrosionresistance. It is noted that the wrap 68 and/or the axial interlock canalternatively be formed in any other suitable manner.

FIGS. 15 and 16 illustrate a preferred method of manufacture for thecable assembly 10. Initially, the conduit abutment fitting assemblies18, 18′ (less the extension members 38, 38′ of the guide tubes 20, 20′)are secured to the cable conduit 14. The cable core 16 is then insertedthrough the conduit 14 and ends of the core 16 are placed into plasticinjection inserts or molds 72, 72′ designed to form the core attachments22, 22′. Once the inserts 72, 72′ are closed and the ends of the core 16are located therein, plastic is injected into the molds 72, 72′ to formthe core attachments 22, 22′ over the ends of the core 16. The finishedplastic core attachments 22, 22′ formed on the ends of the cable core 16are then removed from the molds 72, 72′. The extension members 38, 38′of the guide tubes 20, 20′ are then secured to the joint members 36, 36′of the guide tubes 20, 20′ by wrapping the extension members 38, 38′about the rearward ends of the core attachments 22, 22′ and the forwardends of the guide tube joint portions 38, 38′ and securing the snap lockconnections 46. It is noted that the guide tube extension members 38,38′ are attached after the core attachments 22, 22′ are formed on thecore 16 and thus access to the ends of the core 16 is available whichpermits the over-molding of the core attachments 22, 22′. It is alsonoted that while the above described method describes simultaneouslyover-molding the core attachments 22 on both ends of the core 16,alternatively the core attachments 22, 22′ can be consecutivelyover-molded on one end and then on the other end or a core attachmentcan be over-molded on only one end of the core 16. Over-molding the coreattachments 22, 22′ consecutively or over-molding only one of the coreattachments would allow the use of other types of core attachments onthe other end as may be desired in some circumstances.

FIG. 17 illustrates a push-pull cable assembly 100 according to a secondembodiment of the present invention wherein like reference numbers areutilized to show like structure. The cable assembly 100 according to thesecond embodiment is substantially the same as the cable assembly 10according to the first embodiment described hereinabove except that theconduit abutment fitting 102 and guide tube 104 form an external swiveljoint 106 (that is, external of the conduit abutment fitting 102) whichstill permits the guide tube to be attached after the core attachments22, 22′ are over-molded or otherwise secured to the ends of the core 16.It is noted that the cable assembly 100 according to the secondembodiment utilizes fewer components. It is also noted that the cableassembly 100 is provided with an adjuster 25 but can alternatively beprovided with any other suitable type of adjuster.

As best shown in FIG. 18, the illustrated conduit abutment fittings 102,102′ are each provided with a forwardly-extending external ball 108 andthe rear ends of the illustrated guide tubes 104, 104′ are each providedwith a socket 110 to form the ball and socket or swivel joints 106, 106′so that the guide tubes 104, 104′ can pivot relative to the conduitabutment fittings 102, 102′. The illustrated ball 108 is provided acentral opening or passage 112 which permits the passage of the core 16therethrough. Because the assemblies at the ends of the illustratedcable assembly 100 are substantially the same with respect to theremaining description, only the first end will be described in detailhereinafter.

As best shown in FIGS. 19 and 21, the illustrated guide tube 104 isgenerally tubular-shaped having a generally cylindrical-shaped outersurface and a longitudinally extending central opening or passage 114.At least a forward portion of the passage 114 is sized and shaped forclose sliding receipt of the core attachment 22 therein. The rearwardend of the passage 114 forms the socket 110 which is sized and shapedfor receipt of the ball 108 of the conduit abutment fitting 102 to formthe ball and socket or swivel joint 106.

The illustrated guide tube 104 has a first or left portion 104 a and asecond or right portion 104 b that cooperate to form the generallytubular-shape of the guide tube 104. The first and second portions 104a, 104 b have a parting plane that is parallel to and contains thecentral axis 42 of the passage 112. The illustrated first and secondportions 104 a, 104 b are connected by a “living” or unitary hinge 116located at a rearward end of the guide tube. The living hinge 44 enablesthe guide tube 104 to be formed as a unitary single component that canbe folded over or wrapped around the ball 108 of the conduit abutmentfitting 102 and the core 16 in a lateral direction rather than axiallyextending the core 16 through the passage 112 as described in moredetail hereinafter. FIG. 20 illustrates that a guide tube 105 formed astwo separate components can alternatively be utilized. It is also notedthat the guide tube 105 can alternatively have more than two portionsforming the passage 104. The illustrated first and second portions 104a, 104 b are also provided with a plurality of snap-lock connections 118which secure the first and second portions 104 a, 104 b together aboutthe conduit abutment fitting ball 108 and the core 16. The illustratedfirst and second portions 104 a, 104 b are provided with three snap-lockconnections 118: two at a forward end of the guide tube 104 at oppositesides of the passage 112 and one at a rearward end of the guide tube 104at a side of the passage 112 opposite the hinge 116. It is noted thatany other suitable quantity of snap-lock connections 118 canalternatively be utilized and/or that any other suitable type ofconnections can alternatively be utilized. The guide tube 104 ispreferably of unitary construction and is preferably molded of a plasticmaterial but any other suitable material can be alternatively utilized.

FIGS. 22 and 23 illustrate a preferred method of manufacture for thecable assembly 100 according to the second embodiment of the invention.Initially, the conduit abutment fitting assemblies 18, 18′ (less theguide tubes 104, 104′) are secured to the cable conduit 14. The cablecore 16 is then inserted through the conduit 14 and ends of the core areplaced into plastic injection inserts or molds 72, 72′ designed to formthe core attachments 22, 22′. Once the inserts 72, 72′ are closed andthe ends of the core 16 are located therein, plastic is injected intothe molds 72, 72′ to form the core attachments 22, 22′ over the ends ofthe core 16. The finished plastic core attachments 22, 22′ formed on theends of the cable core 16 are then removed from the molds 72, 72′. Theguide tubes 104, 104′ are then secured to the balls 108, 108′ of theguide the conduit abutment fittings 102, 102′ by wrapping the guidetubes 104, 104′ about the rearward ends of the core attachments 22, 22′and the balls 108, 108′ and securing the snap lock connections 118. Itis noted that the guide tubes 104, 104′ are attached after the coreattachments 22, 22′ are formed on the core 16 and thus access to theends of the core 16 is available which permits the over-molding of thecore attachments 22, 22′. It is also noted that while the abovedescribed method describes simultaneously over-molding the coreattachments 22 on both ends of the core 16, alternatively the coreattachments 22, 22′ can be consecutively over-molded on one end and thenon the other end or a core attachment can be over-molded on only one endof the core 16. Over-molding the core attachments 22, 22′ consecutivelyor over-molding only one of the core attachments would allow the use ofother types of core attachments on the other end as may be desired insome circumstances.

It is apparent from the foregoing disclosure that the cable assembliesaccording to the present invention permits easy formation of plasticcore attachments and eliminates costly steel components and theirassociated costly manufacturing steps. Because at least a portion of theguide tube which covers the end of the core attachment can be laterallysecured about the core, there is increased access to the juncturebetween the core attachment and the core. This permits the ability tomanufacture the cable assemblies with different methods of constructionfor the core attachments which in turn permits multiple designs for thecore attachments that were previously unobtainable or cost prohibitive.Additionally, the cable assemblies of the present invention reduce thenumber of components required and allow for the completion of the guidetubes as the final step. Furthermore, the cable assemblies according tothe present invention enable the production of an entirely plastic ornearly entirely plastic cable assembly for reduced cost and weight andimproved corrosion resistance.

From the foregoing disclosure and detailed description of certainpreferred embodiments, it will be apparent that various modifications,additions and other alternative embodiments are possible withoutdeparting from the true scope and spirit of the present invention. Theembodiments discussed were chosen and described to provide the bestillustration of the principles of the present invention and itspractical application to thereby enable one of ordinary skill in the artto utilize the invention in various embodiments and with variousmodifications as are suited to the particular use contemplated. All suchmodifications and variations are within the scope of the presentinvention as determined by the appended claims when interpreted inaccordance with the benefit to which they are fairly, legally, andequitably entitled.

1. A motion transmitting cable assembly comprising, in combination: acable having a conduit and a core longitudinally movable within theconduit; a core attachment secured to an end of the core; and whereinthe core attachment is molded of plastic and is over-molded onto the endof the core.
 2. The cable assembly according to claim 1, wherein thecore attachment includes a terminal and a rod molded as a unitarycomponent and the core extends within the rod for at least a portion ofthe length of the rod.
 3. The cable assembly according to claim 2,wherein the core extends within the rod for at least the entire lengthof the rod.
 4. The cable assembly according to claim 3, wherein the coreextends within the rod for the entire length of the rod and a portion ofthe terminal.
 5. The cable assembly according to claim 2, furthercomprising a conduit abutment fitting and a guide tube extending fromthe conduit abutment fitting and slidably receiving the rod therein,wherein an end of the core attachment is located within the guide tubeand the core extends into the guide tube to the core attachment, andwherein at least a portion of the guide tube is adapted to be laterallyattached over the core attachment and the core at the juncture of thecore attachment and the core.
 6. The cable assembly according to claim1, wherein the core is provided with an upset within the coreattachment.
 7. The cable assembly according to claim 1, wherein the endof the core is provided with a wrap within the core attachment.
 8. Thecable assembly according to claim 7, wherein the wrap comprises wire. 9.The cable assembly according to claim 7, wherein the wire wrap formsgaps filled with plastic of the core attachment.
 10. The cable assemblyaccording to claim 1, wherein the core comprises nonmetallic material.11. The cable assembly according to claim 10, wherein the conduitcomprises only nonmetallic materials.
 12. A motion transmitting cableassembly comprising, in combination: a cable having a conduit and a corelongitudinally movable within the conduit; a core attachment secured toan end of the core; a conduit abutment fitting secured to an end of theconduit; wherein the core attachment is molded of plastic and isover-molded onto the end of the core; wherein the core attachmentincludes a rod with the core extending within the rod for at least aportion of the length of the rod; a guide tube extending from theconduit abutment fitting and slidably receiving the rod therein, whereinan end of the core attachment is located within the guide tube and thecore extends into the guide tube to the core attachment; and wherein atleast a portion of the guide tube is adapted to be laterally attachedover the core attachment and the core at a juncture of the coreattachment and the core.
 13. The cable assembly according to claim 12,wherein the core attachment further includes a terminal and is molded asa unitary component.
 14. The cable assembly according to claim 12,wherein the core extends within the rod for at least the entire lengthof the rod.
 15. The cable assembly according to claim 12, wherein thecore is provided with an upset within the core attachment.
 16. The cableassembly according to claim 12, wherein the end of the core is providedwith a wrap within the core attachment.
 17. The cable assembly accordingto claim 16, wherein the wrap comprises wire.
 18. The cable assemblyaccording to claim 16, wherein the wire wrap forms gaps filled withplastic of the core attachment.
 19. The cable assembly according toclaim 12, wherein the core comprises nonmetallic material.
 20. The cableassembly according to claim 19, wherein the conduit comprises onlynonmetallic materials.
 21. A motion transmitting cable assemblycomprising, in combination: a cable having a conduit and a corelongitudinally movable within the conduit; a core attachment secured toan end of the core; a conduit abutment fitting secured to an end of theconduit; wherein the core attachment is molded of plastic and isover-molded onto the end of the core; wherein the core is provided withat least one of an upset and a wire wrap within the core attachment;wherein the core attachment includes a terminal and a rod extending fromthe terminal and is molded as a unitary component; wherein the coreextends within the rod for at least a portion of the length of the rod;a guide tube extending from the conduit abutment fitting and slidablyreceiving the rod therein, wherein an end of the core attachment islocated within the guide tube and the core extends into the guide tubeto the core attachment; and wherein at least a portion of the guide tubeis located is adapted to be laterally attached over the core attachmentand the core at a juncture of the core attachment and the core.
 22. Thecable assembly according to claim 19, wherein the core comprisesnonmetallic material.
 23. The cable assembly according to claim 19,wherein the conduit comprises only nonmetallic materials.
 24. Apush-pull motion transmitting cable assembly for a motor vehicle, saidcable assembly comprising, in combination: a cable having a conduit anda core longitudinally movable within the conduit; a core attachmentsecured to an end of the core; and wherein the conduit comprises onlynonmetallic materials.
 25. The cable assembly according to claim 24,wherein the core comprises only nonmetallic material.
 26. The cableassembly according to claim 25, wherein the core attachment is molded ofplastic and is over-molded onto the end of the core.